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INSTRUCTION BOOK M6831
INTRODUCTION 1-1
A-1
B-1
Bibby Scientific Limited. Beacon Road, Stone, Staffordshire ST15 0SA, Great Britain. Tel: +44(0)1785 812121 Fax: +44(0)1785 810405
Bibby Scientific RAK 15/2 Instruction Book M6831 issue 2.3
Bibby Scientific RAK 15/2 Instruction Book M6831 issue 2.3
OPERATOR’S AND UNIT MAINTENANCE MANUAL FOR HEATER, WATER AND RATION (HWR)
RAK 15/2
REPORTING ERRORS AND RECOMMENDING IMPROVMENTS
You can help improve this manual. If you find any error or if you know a way to improve the procedures, please let us know. Mail your letter, Recommended Changes to Publications direct to: Bibby Scientific Limited.Beacon Road, Stone, Staffordshire ST15 0SA, Great Britain.
Page
CHAPTER 1 INTRODUCTION……………………………………………………………. 1 – 1
Section I General Information………………………………………………………… 1 - 3 Section II Equipment Description…………………………………………………… 1 – 5 Section III Principals of Operation…………………………………………………… 1 – 11
CHAPTER 2 OPERATING INSTRUCTIONS…………………………………………… 2 – 1
Section I Description and Use of Operator’s Controls and Indicators……… 2 – 2 Section II Preventive Maintenance Checks and Services (PMCS)…………… 2 – 3 Section III Operation Under Usual Conditions…………………………………… 2 – 7 Section IV Operation Under Unusual Conditions………………………………… 2 – 20
CHAPTER 3 OPERATOR MAINTENANCE INSTRUCTIONS………………………… 3 – 1
Section I Operator’s Troubleshooting Procedures……………………………… 3 – 2 Section II Operator’s Maintenance Procedures…………………………………. 3 – 6
CHAPTER 4 UNIT MAINTENANCE INSTRUCTIONS………………………………… 4 - 1
Section I Repair Parts; Measurement Equipment……………………………… 4 – 1 Section II Service Upon Receipt……………………………………………………. 4 – 2 Section III Preventative Maintenance Checks and services (PMCS)………… 4 – 2 Section IV Unit Troubleshooting Procedures……………………………………… 4 – 6 Section V Unit maintenance Procedures…………………………………………… 4 – 11 Section VI Preparation for Storage or Shipment…………………………………… 4 - 25
Bibby Scientific RAK 15/2 Instruction Book M6831 issue 2.3
Bibby Scientific RAK 15/2 Instruction Book M6831 issue 2.3
TABLE OF CONTENTS (Continued)
APPENDIX A MAINTENANCE ALLOCATION CHART (MAC)………………………… A – 1
Section I Introduction………………………………………………………………… A – 1 Section II Maintenance Allocation Chart…………………………………………… A – 2
APPENDIX B REPAIR PARTS……………………………………………………………… B – 1
Section I Repair Parts List…………………………………………………………… B - 1
Bibby Scientific RAK 15/2 Instruction Book M6831 issue 2.3
a/(b blank)
HOW TO USE THIS MANUAL.
Depending upon the particular requirement, the information contained in this manual can be accessed by using any of the following three methods:
a. Front Cover Index. Using the front cover index and corresponding page locator “bleeds” to access the required chapter or appendix. The first page of each chapter contains an index which provides a listing of the chapter contents. The first section or paragraph in each appendix provides a description of the purpose and contents of the appendix.
b. List of Contents. Using the Table of Contents to obtain the page number associated with the
required chapter, section or appendix.
The following brief descriptions of the major divisions of the manual are provided as a general guide to where information can be found:
Chapter 1 - Introduction. This chapter provides general information and gives a brief description of
the HWR and its purpose. Chapter 2 - Operating Instructions. This chapter describes the operator’s controls and indicators, operator’s
PMCS and operation of the HWR under usual / unusual conditioned. Chapter 3 - Operator maintenance Instructions. This chapter contains the lubrication instructions, troubleshooting
procedures and maintenance procedures which can be performed by operating personnel.
Chapter 4 - Unit Maintenance Instructions. This chapter contains the repair, service and receipt, check procedures,
unit PMCS, troubleshooting procedures, maintenance and preparation for storage and shipment which can be performed by unit maintenance personnel.
Appendix A - Maintenance Allocation Chart (MAC). This appendix includes the maintenance allocation chart which designates
overall authority and responsibility for the performance of maintenance functions on end items or components.
Appendix B - Repair Parts. This appendix illustrates and list the authorised replacement parts for the
HWR.
WARNING
FIRST AID. Never work on the HWR unless there is another person present who is competent in administering first aid. The absence of first aid can result in serious personal injury or even death.
ELECTRIC SHOCK. Do not be misled by the term “low – voltage”. Whenever possible turn of and disconnect the HWR power supply before performing any work. Potentials as low as 30 V DC can cause severe electric shock or death under adverse conditions.
HEALTH HAZARD. Use the HWR to HEAT water only or to HEAT unopened pre-packaged food and water. Using the HWR to prepare, boil, fry or cook food can be a hazard to health.
HIGH TEMPERATURES. Be aware that normal operating temperatures within the HWR are
up to 88C and can reach higher temperatures under abnormal conditions. Always use gloves or other hand protection as necessary. Unprotected exposure to high temperatures can cause serious burn injuries.
OVERPRESSURE. Do not open the cover lid if the pressure relief valve is making a “hissing” noise or venting steam. Set the LO/ OFF / HI switch to OFF, wait until the noise or steam has stopped then open the cover with extreme care using gloves or other hand protection as necessary. Failure to comply can result in serious burn injuries.
HYGIENE WATER. Always cool heated water by adding sufficient cold potable water before using for hygiene purposes. Heated water can cause seriouse scalds and burn injuries.
HEATED WATER. When dispensing heated water, always use a sutible vessel and avoid contact with the tap spigot which might be extremely hot. Failure to comply can result in serious burn injuries.
WATER SPILLAGE. Always ensure that the cover is properly closed and latched before operating the HWR or at any time the host vehicle is mobile. Failure to secure the cover lid can result in accidental spillage of water.
OVERFILLING (1). When heating water only, do not fill the outer container above the one gallon level. Overfilling can result in the accidental spillage of heated water.
OVERFILLING (2). When heating water and unopened rations, do not fill the outer container above the 40 fluid ounce fluid level. Overfilling can result in the accidental spillage of heated water.
WATER / FOOD CONTAMINATION (1). Only use the inner container for carrying, holding and heating clean potable water or heating unopened rations. Using the inner container for any other purpose (eg, personal hygiene) can result in contamination of water or food.
WATER / FOOD CONTAMINATION (2). Always ensure that the inner container and cover lid are clean before fitting them to the HWR. Dirt or other debris will result in the contamination of water or food.
NON-POTABLE / DIRTY WATER (1). Only use clean, potable water when filling the outer container. Non-potable or dirty water can cause contamination of water or food.
NON-POTABLE/DIRTY WATER (2). Only use clean, potable water when cleaning the HWR. Non-potable or dirty water can cause contamination of water or food.
Bibby Scientific RAK 15/2 Instruction Book M6831 issue 2.3
INSTILLATION REQUIREMENTS.
To meet EMC criteria, the RAK15 product should be installed using the three mounting studs to secure the unit via the mounting cradle to the vehicle chassis (Negative ground).
Bibby Scientific RAK 15/2 Instruction Book M6831 issue 2.3
CHAPTER 1
Section I GENERAL INFORMATION ............................................................................................................. ..1-3
1-1 Scope ....................................................................................................................................... 1-3 1-2 Safety, Care and Handling ....................................................................................................... 1-3 1-3 Preparation for Storage or Shipment ....................................................................................... 1-4 1-4 Common Name/Official Nomenclature Cross-reference List ................................................... 1-4 1-5 List of Abbreviations ................................................................................................................. 1-4
Section II EQUIPMENT DESCRIPTION AND DATA ........................................................................................ 1-5
1-6 Equipment Characteristics, Capability and Features ............................................................... 1-6 1-6 Location and Description of Major Components ...................................................................... 1-6 1-7 Equipment Data ........................................................................................................................ 1-7
Section III PRINCIPLES OF OPERATION ......................................................................................................... 1-8
1-8 HWR Functional Description .................................................................................................... 1-9
Bibby Scientific RAK 15/2 Instruction Book M6831 issue 2.3
Figure 1-0 Heater, Water and Ration (HWR)
1-2
Section I. GENERAL INFORMATION
a. Type of Manual. Operators and Unit Maintenance Manual.
b. Model Number and Equipment Name. RAK15/2. Heater, Water and Ration (HWR).
c. Purpose of Equipment.
(1) The HWR provides a mounted potable water and pre-packaged rations heating facility for the crew of
any military vehicle which has a 22 - 28 V dc (24 V dc nominal) electrical system. Operation is possible
at any time (including full battle conditions) in any climate while stationary or mobile.
(2) When used for water only the HWR can heat up to one gallon of potable water for beverages,
hygiene or medical purposes.
(3) When used for rations the HWR can heat up to five unopened pre-cooked meals together with 1.18
liters of potable water.
(4) With the cover closed and locked the HWR can keep the contents hot for as long as operationally
required.
1-2. SAFETY, CARE AND HANDLING
a. The HWR uses a power supply of 22 - 28 V dc (24 V dc nominal). Ensure that the power supply is
turned off whenever the HWR is not being operated. Use extreme care if it is necessary to perform
troubleshooting or maintenance procedures with the power supply connected.
b. The maximum temperature within the HWR will be 71 C or 88 C during normal operation and can
reach 96 C during overheat conditions before automatic shutdown occurs. Take care to avoid burns if
the cover is opened immediately after the HWR has been in operation and be aware that internal heat
can be retained for long periods when the cover is kept closed.
c. Use standard hand tools when tightening bolts, nuts and screws and only tighten with sufficient
torque to ensure that the associated part is held firmly in position.
d. Ensure that the latch hook is properly engaged with the flat center part of the fold-down wire handle
before using the cover to remove the inner container and its contents from the HWR.
e. To avoid accidental damage or contamination, ensure that the cover and inner container are placed
in a safe, clean location when removed from the HWR.
1-3
1-3. PREPARATION FOR STORAGE OR SHIPMENT
Preparation of the HWR for storage or shipment is covered in Chapter 4, Section VII.
1-4. COMMON NAME/OFFICIAL NOMENCLATURE CROSS-REFERENCE LIST
A cross-reference between the common names used throughout this manual and the official nomenclature is
provided in the following listing:
COMMON NAME OFFICIAL NOMENCLATURE
Main Case Main Case Assembly
Latch Latch Assembly
PCB PCB Assembly
Tap Tap Assembly
Heater Heater Assembly
Cover Cover Assembly
1-5. LIST OF ABBREVIATIONS
Refer to Section I of the Glossary for an alphabetical list of the abbreviations used in this manual and their
exact meaning.
Section II. EQUIPMENT DESCRIPTION AND DATA
1-6. EQUIPMENT CHARACTERISTICS, CAPABILITIES AND FEATURES
a. Characteristics.
(1) Operates in any military vehicle with a 22 - 28 V dc (24 V dc nominal) power supply.
(2) Switch-selected low (LO) heating range of 66 - 71 C.
(3) Switch-selected high (HI) heating range of 82 - 88 C.
(4) Switch-selected OFF setting.
(5) Automatic protection against power supply reverse polarity connection and overvoltage surges.
(6) Automatic shutdown protection against power supply under voltage condition.
(7) Automatic shutdown protection against overheat and "boil-dry" conditions.
(8) Non-spill operation under all conditions of service.
b. Capabilities.
(1) Heats up to one gallon of potable water.
(2) Heats up to five pre-cooked meals, or equivalent unopened pre-packaged food, and 1.18 litres of
potable water.
(3) Keeps contents hot for extended periods of time when the cover is closed and latched.
c. Features.
(1) Visual indication of power and heating status.
(2) Dual-action pressure/vacuum relief facility for safe operation.
(3) Insulated for reduced heat loss and the safety of personnel.
1 - 5
1-6. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
1 MAIN CASE. Stainless steel open-box structure which acts as the outermost housing insulated by
preformed fiber blocks. Three stainless steel 5/16 inch fixing studs (with appropriate fixings) enable secure
installation in the host vehicle. The top edge is fitted with a shaped flexible rubber seal which engages with a
matching seal on the cover to form a steam/watertight joint when the latter is closed and latched. The bottom
of the case is closed by a welded base plate which has four preformed "feet" for mounting.
1 – 6
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS (Continued)
2 OUTER CONTAINER. Food-quality seamless stainless steel vessel which is capable of holding up to one
gallon of potable water (inner container removed) or 1.18 litres of potable water (inner container in place). An
integral heater is externally attached to the bottom surface and water can be drained-off by means of a
dispensing outlet which operates in conjunction with the tap.
3 COVER. Moulded plastic cookware with internal air cavities acting as heat barriers and fitted with a
removable pressure/vacuum relief valve. The rear edge locates with a hinge pivot bar on the main case and
the front edge carries a metal hook which engages with the latch. The bottom edge is fitted with a shaped
flexible rubber seal which engages with a matching seal on the main case to form a steam/watertight joint when
closed and latched. When removed the cover allows user access to the inner and outer containers and also
acts as a suitable lifting device for the inner container.
4 INNER CONTAINER. Food-quality seamless stainless steel vessel which is capable of holding up to five
unopened MRE entrees or equivalent unopened pre-packaged food. The container locates within the outer
container and has a fold-down wire handle to facilitate lifting either by hand or by means of the metal hook on
the cover. The handle can easily be removed for cleaning or sanitizing purposes.
5 LATCH. Quick-release toggle clip which, in conjunction with the hook on the cover, holds the cover securely
in position under all conditions. The latch mechanism self-locks in the "fully-down" position and will release
only after upward pressure is applied to a slide-action unlocking button.
6 TAP. Spring-loaded pull-to-operate valve which allows water to be drained from the outer container and
dispensed via a spigot. Protection of the operator against accidental burning is provided by a heatproof plastic
shroud.
7 CONTROL PANEL. Provides for the connection of the power supply and carries the operator electrical
controls and indicators. The panel is sealed to the main case by a flat silicone rubber gasket and is easily
removable for repair at Unit level.
1-7. EQUIPMENT DATA
a. Physical Data.
Width .......................................................... 216 mm.
Depth .......................................................... 292 mm.
Weight ........................................................ 7.7 kg.
position.
Latch (main case + cover) ..........................Self-locking quick-release toggle clip + hook.
Lifting handle (cover)..................................Fold-down heatproof grip.
1 – 7
1-7. EQUIPMENT DATA (Continued)
Supply current .......................................10 A (min)/15 A (max).
Power consumption ..............................300 W (nominal).
Heater type ...........................................Resistive element affixed to the underside of the
outer container.
temperature). On/off switching determined by LO
and HI temperature sensors using thermal
feedback.
Non-repairable thermal fuse operating at 175 C.
d. Performance Data.
56 C in one hour (max) at an ambient temperature
of 21C using HI switch setting.
Heating (rations + water)......................Temperature of up to five pre-cooked meals and
1.18 litres of water will be raised to between 66 C
and 71 C at an ambient temperature of 21 C using
HI switch setting.
Hours. After HWR is turned off with the cover closed
and latched.
Automatic shutdown .............................Power supply voltage less than 22 V dc.
Internal temperature greater than 96 C.
"Boil-dry" condition detected.
e. Environmental Data.
Humidity (storage) .................................Between 10 and 90%.
Section III. PRINCIPLES OF OPERATION
1-8. HWR FUNCTIONAL DESCRIPTION
a.PL1. Electrical connector which accepts the 22 - 28 V dc power supply via a suitable power cable
(not part of the HWR) from the host vehicle electrical system.
b.Input Circuit. Electronic network which protects against reverse polarity connection of the power
supply and overvoltage surges in excess 39 V dc.
c.16 V Power Supply. Provides a stabilized supply of +16 V dc to power the electronic
circuits.
d. Low Voltage Detector. Electronic circuit which monitors the power supply and activates the heater
off latch if the voltage level falls below 22 V dc.
1 – 8.
1-8 HWR FUNCTIONAL DESCRIPTION (Continued)
Block Schematic
1 – 9
1-8. HWR FUNCTIONAL DESCRIPTION (Continued)
e. Boil-dry Sensor. Temperature-dependent network which directly monitors the heater temperature and
outputs a corresponding signal to the boil-dry detector. The sensor is mechanically a part of the heater.
f. Boil-dry Detector. Monitors the output from the boil-dry sensor and activates the heater off latch when the
signal represents a heater temperature of 172 C.
g. Heater Off Latch. Electronic circuit which is enabled by the V+ supply when the LO/OFF/HI switch is set to
LO or HI. In operation the circuit is latched "off" to disable the heater control circuit and thereby prevent heating
operation if the power supply is less than 22 V dc or if the internal temperature is greater than 96 C.
NOTE
If the circuit has been latched in the "off" condition it will need to be
"unlatched" by first setting the LO/OFF/HI switch to OFF (to remove the V+
supply) then selecting the LO or HI heating range as required.
h. POWER ON Lamp. Green LED which lights to provide visual indication that the power supply is turned on
when the LO/OFF/HI switch is set to the LO or HI position.
i. LO Sensor. Temperature-dependent network which provides a control input to the heater control circuit
when selected via the LO position of the LO/OFF/HI switch. The sensor measures thermal feedback from the
outer container and thereby maintains the internal temperature within the LO heating range.
j. HI Sensor. Temperature-dependent network which provides a control input to the heater control circuit when
selected via the HI position of the LO/OFF/HI switch. The sensor measures thermal feedback from the outer
container and thereby maintains the internal temperature within the HI heating range.
k.LO/OFF/HI Switch. Operator-controlled 3-position toggle switch with a center OFF position. Selects a
heating range of 66 - 71 C when set to the LO position or a heating range of 82 - 88 C when set to the HI
position. If the power supply is turned on, the switch also lights the POWER ON lamp and enables the heater
off latch when set to the LO or HI position.
l. Heater Control. Electronic circuit which normally provides on/off relay switching of the heater in response to
the control input received from the LO or HI sensor via the LO/OFF/HI switch (ie, acts as a thermal servo). The
circuit can also be disabled by the heater off latch or the overheat sensor in order to prevent heating operation
under abnormal conditions.
m. HEATER ON Lamp. Yellow LED which lights to provide visual indication that power is being applied to the
heater.
n. Heater. Comprises a 28 V, 15A heating element which supplies conductive heat to the outer container
when power is applied from the heater control circuit. The heater is protected by a non-repairable thermal
fuse which operates at a temperature of 175 C.
o. Overheat Sensor. Temperature-dependent network which monitors conductive heat from the outer
container and disables the heater control circuit if the temperature rises above a level of 96 C. This action is
delayed by approximately one minute in order to avoid spurious operation.
1 – 10
CHAPTER 2
OPERATING INSTRUCTIONS
Section I DESCRIPTION AND USE OF OPERATOR’S CONTROLS AND
INDICATORS.................. Page
2-3 General................................................................................................................................ 2-3 2-4 PCMS Procedures............................................................................................................... 2-4 2-5 Cleaning Agents.................................................................................................................. 2-4
Section I. DESCRIPTION AND USE OF OPERATOR'S CONTROLS AND INDICATORS
2-1. GENERAL
The HWR has been designed for installation in a variety of military vehicles and for operation under a wide
range of conditions. Operating personnel should be aware of any peculiarities or operational limitations which
are applicable to their particular installation.
2-2. OPERATOR'S CONTROLS AND INDICATORS
The operator's controls and indicators are all located on the front of the HWR.
1 LO/OFF/HI switch (3-position)
Selects heating range of 66 - 71 °C when set to the LO position.
Deselects heating…